Method and apparatus for the manufacture of candles



Oct. 3, 1961 A. WRIGHT 3,002,221

METHOD AND APPARATUS FOR THE MANUFACTURE OF CANDLES Filed May 19, 1954 4 Sheets-Sheet 1 //7 van/0r:

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METHOD AND APPARATUS FOR THE MANUFACTURE OF CANDLES Filed May 19, 1954 4 Sheets-Sheet 5 Oct. 3, 1961 A. WRIGHT 3,002,221

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3,002,221 METHGD APPTUS FOR THE UFACTURE F CANDLES Arthur Wright, 68 Lookout Road, Mountain Lakes, NJ. Filed May 19, 1954, Ser. No. 430,900 15 Claims. (Cl. 18-1) This invention relates to candles and method and apparatus for the manufacture thereof.

It is a principal object of this invention to provide method and apparatus whereby candles may be manufactured more expeditiously and more economically as compared with prior practice. A further object of this invention is to provide candles and method and apparatus for making them that are superior to candles heretofore produced by conventional methods and apparatus.

Devotional wax candles of the type which have extensive religious usage have heretofore been produced by casting molten wax into a candle mold wherein the wax is permitted to cool until it' has become solidified in the form of a candle body. When the candle is of the type which comprises a base for supporting the wickin upstanding position when the wax is molten during burning it has been usual practice to cast the candle body about a centrally disposed pin which is removed after the wax has solidified and thereafter to insert the wick through the hole left by the withdrawn pin. At the same time the base for holding the wick is caused to be held at the bottom of the candle by some suitable means such as small .tangs or other projections from thebase that bite into the wax at the bottom of the candle. In order that the casting operation may notrequire an excessive amount of time, the molds into which the wax is cast are normally provided with chilling means, as, for example, a hollow jacket through which a cooling fluid can be passed. However, even in such case the cooling requires an undesirably large amount of time. Moreover, the cooling liquid tends to condense moisture from the air which becomes entrapped in the molds, with resultant production of checks, pits, cavities and other unsightly irregularities along the sides of candles so molded. Likewise, when the molten wax cools it tends to contract to a very substantial extent and when it contracts so as to become separated from the side wall of the mold the periphery of the candle is correspondingly non-uniform. The contraction also is troublesome for the further reason that when the wax is initially solidified with upper portion of the molded wax candle body tends to become concave. The end of the candle which is to be the top, i.e., the end to be lighted, is usually disposed so as to be at the bottom of the mold in order that it will receive its proper shape notwithstanding contraction of the wax'at the opposite end. To counteract the contraction during cooling that tends to result in a concavity, it is common practice to initially overfill the molds used and then after the cast candle body has cooled in the mold scrape off excess wax leaving a nearly flat surface. Another difiiculty that frequently occurs in the manufacture of devotional candles by conventional methods is the tendency for some air to become entrapped. Air, if entrapped, tends to concentrate in some zone of the candle body in the form of relatively large bubbles which result in corresponding relatively large hollow spaces in the candle body after the wax has solidified.

The foregoing is with principal reference to the manufacture of devotional candles which are designed to burn for some period ranging from about two to ten hours. In the case of those devotional candles which are larger and which are intended to burn for several days, it has been the usual practice to cast the candle directly into Patent C) been produced.

the container in which the candle is to be burned, the melted wax being cast after having previously placed a wick and base therefor in the container. in such case the difficulties and disadvantages hereinabove mentioned are also encountered except that the shrinkage of the wax upon cooling occurs at the top of the candle rather than at the bottom and it is so great as to result in a very substantial concavity. Accordingly a second pouring of molten wax is utilized to fill the concavity so that the wax will be substantially flat at the upper end of the candle.

The casting method for making devotional candles of the smaller type hereinabove mentioned also is generally utilized in the manufacture of candles which are not intended for ornamental use and are intended primarily for their functional utility as, for example, by workmen.

Ornamental candles such as those used in residences are generally made by the dipping method, namely, by repeatedly dipping a vertically held wick in molten wax with an accumulation of a thin layer of wax upon each dip which is permitted to harden when the wick has been removed from the bath of molten wax. The dipping is continued and the manipulations are carried out until a candle having the desired length and shape has Frequently the inner core of such a candle is made using one type of wax while the outer surface is produced from another type of wax which may be used to provide a desired color or a wax of higher melting point intended to minimize dripping. The dipping method of making candles is a cumbersome and costly one. a

It is a feature of this invention that instead of casting molten wax to produce a candle body, molten wax is reduced to a finely particulate form such that the wax is caused to occur in a friable condition at temperatures well below its melting point, e.g., at atmospheric temperature. This friable mass of wax particles is molded to form candle bodies at temperatures below the melting point of the wax, e.g., at atmospheric temperature, and since there is no chilling step involved the molding can be accomplished very rapidly so as to provide a production rate far in excess of that which is possible when molten wax is cast by pouring it into a mold followed by chilling. Moreover, since there is no chilling or.

other cooling of the wax during molding no problems are presented as regards shrinkage during molding or as regards condensation resulting from the use of chilled surfaces for the purpose of reducing the time required for solidification of a cast body of molten wax.

Another feature of this invention is that the molten wax is reduced to finely particulate form by atomization of molten Wax into a gaseous atmosphere. For reasons of economy, the gaseous atmosphere ordinarily is air. The molten wax which is supplied under pressure is atomized into a stream of air while it is'exp'anding after release from the superatmospheric pressure at which it is supplied to an atomizing device. After atomizing the molten wax so as to provide tiny solid Wax particles, the solid wax particles settle out from the gaseous atmosphere and there is enough of the gaseous atmosphere,- e.g., air, retained among. the particles so that the particles constitute a friable mass notwithstanding the fact that the wax may have a relatively low melting point, such as F.' Moreover, I have found that the mass is of such friability as to penmit its being handled and used for charging candle molds. Preferably, that type of mold is used which is adapted for intermittent formation of a candle body. While the particles together with the air or other gas occluded therewith are friable, the particles may be compacted en masse so as to largely expel air or other gas and cause the particles to adhere together with sufiicient coherence so that a formed candle body may be removed from a mold. Moreover, according to this invention the friable mass of wax particles may be compacted in a mold so as to surround a centrally located wick which is held within the mold when the friable mass of wax particles is charged into the mold. Preferably, the mold which is employed is provided with vent means whereby occluded air or other gas together with excess wax particles are expelled so that the resultant candle body will have both desired dimensions and desired density. The characteristics of the candle which is thus produced are especially desirable when the pressure is controlled so that there is only partial adhesion and co alescence of the particles during compaction in the mold and when the coalescence of the particles progresses thereafter until the wax becomes of substantially continuous phase as the result of tempering, which is preferably accomplished merely by storing candles so produced for one or two days at ordinary room temperature.

Further features of this invention relate to method and apparatus whereby finely particulate wax is produced and collected and is molded into candle bodies. In the molding of the candle bodies the wax particles preferably are subjected to compaction in the direction of disposition of a wick which is furnished from a continuous supply and about which the friable mass of particles is disposed with resultant formation of candle bodies in spaced relation along the wick which is severed while the candle body is held at a separate holding station whereat a wick base for a candle of the devotional type may also be applied if desired.

After the candle body has been produced as hereinabove described according to this invention, the wax has very much the consistency and appearance of a candle produced by casting molten wax except that the wax has a slightly more uniform and somewhat less translucent appearance because of the wax being produced by the coalescence of tiny particles to substantially continuous phase. While a number of tiny porelike bubbles are generally distributed substantially uniformly throughout the wax, the density of the candle body is substantially the same as the density of a candle made from similar wax by the hot casting method. The resulting candle is notable for its dimensional accuracy and its freedom from both surface and internal irregularities which characterize candles that have been cast from molten wax.

The method of this invention is especially adapted for use in the manufacture of candles of the type hereto-fore made by the hot casting method and is of particular utility in the manufacture of devotional candles. However, this invention may also be utilized in the manufacture of a core member which may be utilized in completing the manufacture of an ornamental candle merely by dipping the core for the purpose of providing the outer layers of an ornamental candle which has desired color and consistency.

Further features, objects and advantages of this invention will be apparent from the following description of an illustrative example of the practice of this invention in connection with the following drawings, wherein:

FIG. 1 is a side elevation partly in section showing largely schematically the portion of the apparatus wherein wax is atomized and collected for deposit on a conveyor;

FIG. 2 is a continuation on a larger scale and partly in section of the apparatus shown in FIG. 1, the portion of the apparatus shown in FIG. 2. being that wherein the atomized wax particles are molded for the production of completed devotional candles;

FIG. 3 is a side elevation on a larger scale which shows in greater detail the chamber into which the wax is atomized and in which the atomized wax particles are collected;

FIG. 4 is a largely schematic elevation, partly in section, which is illustrative on an enlarged scale of one 4 type of atomizing means that may be used in the practice of this invention;

'FIG. 5 is a side elevation of a typical devotional candle;

FIG. 6 is a perspective view of one type of wick base for a devotional candle which may be used in the mac tice of this invention;

FIG. 7 is a perspective view of another type of wick base which may be used in the practice of this invention;

FIG. 8 is a side elevation of a conventional type candle which likewise may be made according to this invention;

FIG. 9 is a side elevation of an ornamental type candle, the central body portion of which may be made according to this invention;

FIG. 10 is a side elevation, partly in section, of an other type of devotional candle which may be made according to this invention and which comprises a container for the wax candle body; and

FIG. 11 is a perspective view of one type of base which may be used for supporting the wick of a candle of the type shown in FIG. 10.

In connection with the drawings, it is to be understood that they are for the most part schematic and that the drawings are not to scale, some of the parts having been enlarged relative to others for the purpose of clarity.

The apparatus which is shown in FIGS. 1 to 4 is typical of apparatus for the manufacture of devotional wax candles according to this invention. The wax that is used in the manufacture of devotional wax candles ordinarily is that which is known as white crude scale wax, the wax being a crude mineral wax of the parafiinitic type which usually has a softening point of about 118 F. to about 135 F., e.g., about F. The wax is maintained in a molten, i.e., melted, condition in the supply tank 15 which can be filled utilizing the inlet line 16, as by pumping it in melted condition through the line 16 from a supply truck. The wax is maintained at the proper temperature for atomization by means of the heating coil 17 through which a heating fluid such as water or steam may be continuously circulated at the pump 18 from the heating unit 19 through the lines 2% 21, 22 and 23. The heating fluid from the unit 19 is also used to maintain-at the desired temperature the wax which is pumped by the pump 24 from the tank 15 through the line 25 to the atomization means, which is indicated generally by the reference character 26. The heating fluid from the heating unit 19 is pumped by the pump 27 so as to be circulated through the jacket 28 for the wax line 25 via the lines 20, 29, 30, 31 and 23.

As shown in greater detail in FIG. 4, the molten Wax is directed by the line 25 to the orifice 32 through which the molten wax is discharged. The pressure of the molten wax as supplied to the orifice 32 may be controlled by the pressure control valve 33. The orifice 32 may be opened and closed by the valve 34-.

Air is supplied to the atomizing means by the air pump 35 through the line 36 which is controlled by the pressure control valve 37 therein (FIG. 4). Preferably the air line 36 has a further valve 38 therein whereby control of the air to the atomizing means may be made subject to remote control by any suitable means indicated diagrammatically by the line 38a, e.g., hydraulic, pneumatic, or electric. The air is discharged through the aperture 39 and the wax which is discharged from the aperture 32 is atomized into the stream of moving and expanding air. Preferably there is associated with the nozzle of the atomizing means 26 a heating unit 40 which is connected with electric current supply lines 41 that are controlled by the rheostat 42 by which the amount of heat supplied by the heating device 40 may be varied. The temperature of the atomizing means adjacent the nozzle may be indicated, if desired, as by a suitable indicator which may be appropriate for indicating temperas,oo2,221

ture at a remote point. Such a temperature measuring device is shown as comprising the heat sensitive element 43 which is attached to the wax supply line 25 just prior to the atomizing aperture 32, the device preferably being of an electric type adapted to indicate the temperature at a remote point, i.e., on the temperature indicator 44.

The showing of the wax atomizing means in FIGS. 1, 3 and 4 is largely schema-tic because conventional atomiizing means available on the market may be used. Other types of atomizing means than that shown also may be employed.

As shown in FIGS. 1 and 3, the atomizing means 26 is mounted in the roof-45 of the collecting chamber 46 into which the wax particles produced by the atomizing means are projected. In FIGS. 1 and 3 only one such wax atomizing means is shown. However, for increasing capacity additional wax atomizing means units may be employed. For example, in addition to the unit shown.

in FIGS. 1 and 3 additional units may be installed at stations 47, 48 and 49 which have been indicated in FIG. 3. For supplying a plurality of wax atomizing units, the air and Wax supply lines may be carried in a trough 50 (FIG. 3) around the top of the collecting chamber 46. Each of the units may be connected to common supply lines for wax and air in the trough 50 and any one or more may be employed as desired. For facilitating access to the atomizing units by an attendant, a walk 51 may be provided which may be reached as by the ladder 51a. As a safety precaution, the collecting chamber 46 may be provided with a safety cover 52 and with safetydoors 53 which are such as to be automatically opened if the pressure within the chamber 46 should become excessive.

As indicated in FIG. 1, the wax which is atomized by the atomizing means 26 becomes dispersed in the atmosphere within the chamber 46 and because the atmosphere in which the wax is atomized is substantially below the melting point of the wax, the wax particles settle toward the bottom of the chamber 46 in a solid condition so as to become collected by the collecting pan 54. The collecting pan 54 presents inner surfaces which slope down wardly toward the outlet 55. For facilitating the travel of the collected wax particles, the collecting pan 54 is connected to the side walls of the chamber 46 by a flexible connection 56 which permits vibration of the pan 54 relative to the side walls of the chamber 46 under the influence of the vibrator 57.

The air atomized wax particles become collected on the pan 54 in the form of a friable mass that passes through the outlet 55 together with such air as is being introduced into the chamber 46 through the atomizing means. The wax particles that fall from the outlet 55 are conveyed away by the conveyor belt 58 on which they fall and in so doing they are protected by the shield members 59 and the cover 60 for the conveyor. is permitted to escape over the upper margin of the shield members 59 and if the collecting chamber 46 is installed in the open possible entry of water into the zone within Elie shield members 59 is prevented by means of the guard Referring to FIG. 2, the belt conveyor 58, which may be operated by the motor 62, discharges the friable mass 63 of collected wax particles into the hopper 64 for the pressure molding means whereby the wax particles are compacted into the form of a candle body. In FIG. 2 one type of suitable pressure molding means has been shown, the showing being largely schematic. Depending on the capacity desired, the number of molds may be varied from the three shown in FIG. 2, one of which has been shown partly in section so as to better indicate the structure and the mode of operation.

When using the pressure molding means shown in FIG. 2, the Wax particles in discrete friable condition are fed from the hopper 64 into the funnel-like receiving member 65 of the mold 66 through the chute 67 having an adjustable gate 68 therein for controlling the amount of wax particles chargedv into the funnel shaped receiving member 65. For obtaining more uniform flow of the wax particles, the chute 67 preferably has the vibrator 69 operatively connected thereto and the receiving member 65 has the vibrator 69a associated therewith.

In FIG. 2 the parts are shown in position for receiving the friable mass of wax particles into the funnel shaped receiving member 65 and into the mold 66. When these parts have become filled with the wax particles they are compacted by the piston 70, the under surface 71 of which is shaped so as to give the desired contours to the upper end of a candle. The piston 70 is rigidly held by the rack 72 which is raised and lowered by means of the hydraulic pistons 73 within the cylinders 74. The pistons 73 are hydraulically actuated by fluid under pressure supplied by the pump 75 which is operatively connected to the compound control valve 76 by the supply line 77 and the return line '78 comprising the oil reservoir 78a. The compound control valve 76 may be actuated by any suitable means such as the camlever 79 which, through the lines 80 and 81, controls the relative pressures on the opposite sides of the pistons 73 for effecting the desired movements of the pistons 70.

When starting with the parts in the position shown in FIG. 2 and with the mold 66 filled with the friable mass of wax particles, the piston is first brought down to the position shown in dotted lines in FIG. 2. By virtue of the compaction of the particles and the shape of the mold parts, the wax particles are formed into a candle body within the mold. While the friable mass of wax particles which is charged into the mold 66 contains a substantial amount of occluded air, such air is largely expelled during the compacting stroke of the piston. Moreover, excess wax particles and some of the air are expelled through the vent line 82, the vent line 82 being closed off by the piston 70 just before the piston 70 reaches the end of its compacting stroke, thereby producing candle bodies of uniform height and consistency.

The candle wick 86 is fed from the spool 83 through a central passage 84 in the piston 70 so as to extend down through the bottom of the mold 66 where it is gripped by the shutters 85, which likewise provide the bottom of the mold 66 when the parts are in the position shown in FIG. 2. When the piston 70 is moved to compact the loose wax particles into the form of a candle body, the piston moves longitudinally relatively to the wick 86 and the wax particles are compacted about the centrally disposed wick within the mold. Thus the mass of wax particles is compacted from the portion of the continuous length of wick that they initially surround to only a part thereof, and by repetition of the operation spaced candle bodies are formed on the common length of wick that is supplied.

After the candle body has been formed by compaction of the wax particles about the wick 86 within the mold 66, the shutters which are slidably'mounted under neath the mold 66 are drawn apart by the rods 87 until the bottom of the mold 66 becomes fully opened. After the shutters 85 have thus been drawn apart the piston 70 is again moved downwardly under the influence of the hydraulically actuated pistons 73 so as to move the formed candle body 38 to the position shown where it is held between a similarly curved wall of the plate 89 and the gripping member 90 which is reciprocated by the rod 96a so as to be retracted when the candle body 88 is being moved to the position shown and is advanced to grip the candle body after it has reached the position shown. In being advanced to the position shown, the candle body 88 carries with it the wick about which it has been formed, thus causing additional wick to be unwound from the spool 83. The piston 70 is next actuated by the hydraulic pistons 73 so as to rise to the position shown in solid lines in FIG. 2 and the shutters 85 likewise return to closed position for gripping the Wick 86 l 7 and for receiving the next charge of the wax particles. While the candle body 88 is held in the position shown by the gripping action of the gripping member 98, a clip, such as that shown in either FIG. 6 or FIG. 7, is taken from the magazine 91 by the clip carrier 92 which is mounted for reciprocating movement and is reciprocated by the arm 20a. The clip carrier 92 is adapted when reciprocated to remove one wick base from the magazine 91 and to advance it so as to become frictionally attached to the wick that extends below the candle body 88 in position substantilly flush with the bottom of the candle body 88. During this operation the knife 93 also cuts the wick in adjacent spaced relation to the bottom of candle body 88 so that the previously similarly produced candle body 94 when in the position shown is set free and is permitted to fall onto the receiving slide plate 95' which feeds the completed candles 96 onto the conveyor 97, which takes them away for packaging. A typical completed devotional candle produced as described is shown in FIG. as comprising the candle body 98, the wick 99 and the wick base 1%. The type of Wick usually used in devotional candles consists of a central stiflfening element such as a low melting point lead alloy, antimonywoods metal and the like surrounded by a woven or twisted cotton jacket.

In connection with the foregoing description of the pressure molding means and its operation, any suitable means for eifecting the reciprocation of the parts 87, 90a and 92a and controlling such reciprocation in synchronism with the other movable parts of the apparatus may be employed, e.g., hydraulic means such as that shown for actuating the pistons 70. Likewise, any suitable means may be employed for efiecting at proper time a severing stroke of the knife 93 for cutting the wick.

By utilizing the method and apparatus of this invention as exemplified hereinabove, a devotional candle such as that shown in FIG. 5 which is complete with wick and base may be readily produced at the rate of about ten candles per minute per mold. This rate of production is many times that which is possible using prior methods and apparatus whereby wax is cast in molten condition and is retained in the mold until it is suificiently cooled so that it may be safely removed without excessive deformation. It is apparent, therefore, that according to the applicants invention whereby the wax is first atomized from molten condition and then molded cold while in the form of a friable particulate mass the molding operation can be carried out as rapidly as the pressure molding means may be mechanically operated and that the wax can be produced in the cold friable particulate condition from the molten condition as rapidly as the wax particles can be utilized by the pressure molding unit. More generally, this invention enables both large and small candles to be readily manufactured at rates which are twenty to forty times the rate of production of candles of similar type when using the methods of candle manufacture conventionally employed at the present time.

For atomization the wax is normally heated only to that temperature which is desirable for atomization. It is normally sufiicient to heat the wax to a temperature which is only about to about 50 F. above the melting point of the wax. While the wax might be heated to higher temperatures, this would merely involve the utilization of an unnecessary amount of heat, at least in most instances. As above mentioned, white crude scale wax usually has a melting point in the neighborhood of 125 F. and a good temperature for atomization of such wax is about 150 to about 160 Ff Other types of wax most generally used in candles have a melting point between 125 F. and 190 F. However, there are other types of wax which may be used and the melting point of which may vary from about 105 F. to as high as about 240 F. As aforesaid, the temperature to which the wax is heated for atomization varies with the melting point and it is usually suflicient to heat the wax to only moderately above its melting point, as hereinabove stated. When reference is made herein to the melting point of the wax, the reference is to melting point as determined by the standard A.S.T.M. test No. D87-42.

=For atomizing the wax it has been found that in the case of white crude scale w-ax a pressure of about 6 pounds per square inch is very satisfactory. However, the pressure which is employed may vary quite widely as, for example, from between about 5 pounds per square inch to about 60 pounds per square inch. The air pressure which is used for atomizing the wax may likewise vary over a wide range. In the case of the example hereinabove given using crude scale wax it has been found that air pressure of about 45 pounds per square inch afrords very good atomization. However, desirable results may be obtained when the air pressure is varied from between about 15 pounds per square inch to about pounds per square inch. When the molten wax is atomized into the moving stream of expanding air, the expansion of the air exercises a cooling efiect. If the air pressure is too high, this cooling eifect may be so great as to chill the atomizer unit parts through which the wax is flowing to an undesirably great extent and it is particularly for this reason that the employment of air pressure above about 100 pounds per square inch is usually undesirable. The cooling eifect of the air may be counteracted by the heating element 40 shown in FIG. 4 and it is normally preferable to employ this heating unit so that the nozzle temperature where the molten wax is discharged through the aperture 32 will be appropriate for obtaining the desired atomization. This is particularly desirable in instituting atomization so that the atomizer unit parts in the vicinity of the aperture 32 may be maintained at desired temperature until the flow of the heated wax to these parts, as a result of continued operation, serves either largely or entirely to maintain the atomizer unit parts in the vicinity of the aperture 32 at the temperature which is best suited for effecting atomization. Thus, in normal practice the atomizer parts adjacent the nozzle are heated to a temperature substantially above the melting point of the wax to be atomized prior to instituting atomization and thereafter the temperature is controlled so these atomizer parts are maintained slightly above the melting point of the Wax. The optimum air pressure that is to be employed depends on such factors as the size of the orifice through which the air is discharged, the temperature of the wax in relation to its melting point, and the rate of feed of the melted wax. It is in the interest of economy to employ the lowest air pressure at which satisfactory production of atomized particles can 'be obtained.

By the air atomization step hereinabove described and illustrated the molten wax is produced in a very finely particulate condition wherein the bulk of the wax particles range in size from about .001 inch to about .02 inch. When there is reference to the size of the particles in terms of a fraction of an inch the reference is to the maximum dimension if the particle is other than substantially round. These wax particles when examined under magnification appear, for the most part, round or cubical. As the result of extensive utilization of the wax particles produced by atomization as hereinabove described, it has been found that when collected they form a friable mass which can be readily handled so as to permit their being transferred and charged into a mold. Moreover, the particles have been found to have excellent molding properties and that their surface area and the condition of the air films between the particles prior to molding are such as to permit uniform expulsion of excess air during molding and the establishment of contasting surfaces of particles as a result of the pressure whereby a coalescence of the Wax particles is aflorded notwithstanding that the wax particles are at a temperature substantially below their melting point. After the wax particles have been atomized into the expanding stream of air the wax is at a temperature which is preferably at least about 30 to 35 below the melting point of the wax throughout the balance of the operations. As mentioned above, the air which is supplied under pressure to the atomizing unit becomes cooled when it expands, thus causing the atmosphere within the collecting chamber 46 to be maintained at a temperature well below the melting point of the wax so that the wax is immediately cooled to solid particulate form as it is sprayed into the collecting chamber 46. Throughout the balance of the operations the wax particles may conveniently be maintained at normal atmospheric temperature such as about 60 F. to about 80 F.

During molding it is preferable to use relatively moderate pressure in the production of devotional wax candles from White scale wax and, continuing with the example herein given, a molding pressure of about 45 pounds per square inch has been found to be very desirable. Pressures less than about 40 pounds per square inch ordinarily do not result in as much compaction as desired. On the other hand, if the pressure is increased so as to be greater than about 100 pounds per square inch, the resulting compacted candle body is not as uniform. in consistency as when lower pressures are used. It is believed that this decrease in the uniformity of consistency which results from the employment of molding pressures greater than about 100 pounds per square inch is due to the fact that there is a slight amount of air which is entrapped in the form of tiny air pockets and if the entrapped air is compressed too highly it has a tendency, upon relief of the pressure, to form flakelike discontinuities in the body of the wax. When moderate pressure within the range aforesaid is used, the formed candle body is notable for its uniformity of consistency, texture and appearance. Immediately after formation and discharge from the mold the molded candle body does not possess as much strength as is desired in the candle as sold. Thus, in practicing this invention the wax particles are initially only caused to partially adhere and to partially coalesce While they are in the mold. The candle body while the wax particles are thus in only a partially coalesced condition is discharged from the mold and the particles thereafter are caused to continue to coalesce so as to create a more homogeneous wax structure by the tempering of the candle'bodies after removal from the mold. All that is required ordinarily for tempering is to let the candles stand for one or two days at moderate temperature such as ordinary room temperature. This tempering can be obtained after the candles have been packaged and does not occasion any interference with production rate as regards packaging immediately after molding. The tempering could be accelerated somewhat by mildly heating the candle bodies, but this is unnecessary and usually is undesirable for if'the finished candles are heated much above about 90 F. they are readily deformed and may get out of shape.

As aforesaid, the wax particles in friable discrete condition are preferably molded at a temperature which is at least 30 to 35 below the melting point of the Wax and the molding is desirably caused to occur at normal room temperature. For example, when white crude scale wax is used having a melting point of about 125 F. the molding should take place at a temperature not higher than about 90 F. When the wax particles are produced as aforesaid and are molded under the conditions hereinabove described, the resulting candle body which is produced is notable for the trueness of its dimensions and its flawless surfaces. During the pressure molding of the wax particles the mold is completely filled, and since there is no cooling there is no shrinkage so as to result in pockets, checks or concavities such as characterize candles which have been cast in molten condition. Moreover, during the air atomization of the wax the conditions are such that any moisture if present in separated from the wax and there is no possibility of entrapment of moisture in such a way as to form flaws in or on the surface of the candle body. As hereinabove mentioned, this has been a major source of difiioulty in using molds that are chilled so as to aid in cooling cast molten wax for the chilled molds tend to cause condensation with production of droplets that cling to the inner surfaces of the molds and produce checks and flaws in the sides of the mold. Moreover, as hereinabove said, the condition of the wax and the pressure conditions wherein the pressure is applied gradually with venting of air and excess particles results in retention of only a small amount of en trapped air in the wax, such entrapped air as there is being very uniformly distributed in the form of tiny pores, most of which are so small as not to be discernible with out the assistance of magnification. The best results are obtained when the rate at which the friable mass of wax particles is compacted, through the distance which is the difference between uncompacted mass and the mass that has been compacted to produce, the candle body, is not greater than about 1 inch per second. With ordinary candles of the cast type it is more normal than not for large bubbles of air to become entrapped, particularly along the sides of the candle body, in a way that results in an unattractive appearance. The candle bodies produced according to this invention are free of this drawback and are highly uniform and attractive in appearance both as regards dimensions, surface uniformity and appearance of the wax.

In the practice of this invention the molding means used may be varied depending upon the type of candle product to be produced. For example, when a candle of the type shown in FIG. 8 is to be manufactured which consists merely of the elongated candle body 101 and the centrally disposed wick 102, the apparatus and method hereinabove described may be employed, except that the mold used would be one having greater length in relation to diameter than that shown in FIG. 2 and except that there would be no necessity for providing means for attaching a wick base to the wick at the bottom of the candle. If it should be desired to have the lower end of the candle shown in FIG. 8 tapered, then the mold could be of such character as to provide the desired taper. For example, by inverting the shutter members the candle body that is formed in the mold 66 would be one provided with a tapered base.

In FIG. 9 a candle is shown which is of the decorative type commonly used in residences. The top of candle shown in FIG. 9 comprises the central body portion 103, the wick 104 and an outer wax layer 105. The candle comprises the bottom tapered portion 106 for facilitating the placing of candles of this type in candelabra. As mentioned hereinabove, such candles have heretofore been produced by repeatedly dipping a length of wick in melted wax which is permitted to solidify after each dip until a sufficient body of wax has been built up around the wick. This invention lends itself to the manufacture of candles of this type by molding the central core 103 about the Wick 104 in a single molding operation using wax particles which have been prepared in the form of a friable mass and causing them to be compacted and coalesced in a single molding operation. In forming the core 103 it is possible, as described hereinabove, to directly mold the bottom portion 1% so as to be tapered instead of employing a separate tapering operation, as is the practice in connection with conventional methods for making decorative candles. After the central core has been produced according to this invention then all that remains is to dip the candle a suflicient number of times to provide, the outer Wax layer 105 having the color and other properties which may be desired.

In FIG. 10 a different type of devotional candle is illustrated, this candle being much larger than the other 75 types of devotional candle hereinabove mentioned and ill adapted to burn continuously for several days. As illustrated, this type of candle is normally produced in the form of a wax candle body it within the jar 168, there being a central wick 109 of the self-supporting type hereinabove described which is held by the wick base 110 so as to remain upright even though the wax 107 may become melted in the jar 1%. Instead of making a candle of this type by pouring the melted wax into the jar 1438 in which the wick and wick base have previously been placed, the first pouring being followed by a second pouring to level off the Wax at the top to compensate for the shrinkage which occurs upon cooling, the candle body Hi7 can be formed by the cold molding of a friable mass of wax particles as hereinabove described, so as to surround the centrally disposed wick and so as to have external dimensions such that the molded candle can be fitted within the jar 108. For molding a candle body having the shape of the candle body 107 shown in FIG. 10 the mold which is used is such as to provide the desired shape and in order to facilitate ejection of the molded candle body by further movement in the same direction of the piston which is used to initially compact the mass of wax particles, the mold instead of having only the shutters 85 at the bottom thereof mounted for reciprocatory movement may be longitudinally split throughout so that the mold side walls of the mold 66 will move integrally with the shutters 85. In the manufacture of a candle of the type shown in FIG. 10 a wick base such as that shown in either FIG. 6 or FIG. 7 may be used and the wick base may be mechanically installed in the manner that has been described hereinabove. However, if desired, a wick base of the type shown in FIG. 11 may be used which is adapted to be applied to the wick at the bottom of the candle body by hand by forcing the curved fingers til into the wax around the bottom of the wick and then crimping them together to the position shown in FIG. 10.

In addition to those exemplified herein, candles of other types and shapes may be produced according to this invention. For example, when using a split mold of the type aforesaid novelty candles of irregular shapes can be produced very readily.

While a particular type of molding apparatus and particular molding steps have been disclosed, it is to be understood that this has been done for illustrative purposes and that the pressure molding means that is used for forming a candle body by the cold molding of a friable mass of wax particles may take other forms than those illustrated. Thus, other types of pressure molding means may be employed by which candle bodies are produced intermittently. Alternatively, a friable mass of wax particles may be subjected to continuous pressure molding at a temperature below the melting point of the wax, as by causing the mass to be extruded. Thus, it is possible in the practice of this invention to extrude the wax in the form of a friable mass of particles so that the mass is compacted as it is extruded around a wick that is moved simultaneously with the extruded product. After extrusion the compacted .coherent wax particles are separable from the wick at suitable intervals so as to provide individual candles of desired length that are severable from each other.

While it is preferable and while it is an advantage of this invention that the friable mass of wax particles may be compacted so as to provide a candle body about a centrally disposed wick as a single operation, it is not essential that the candle body he formed about a wick. Thus by employing a mold which is of the type shown, but in which the compacting piston comprises a centrally disposed retractable pin therein, a candle body can be formed by compacting a friable mass of wax particles which has a hole extending therethrough which is adapted for having a wick inserted in the manner that is currently common practice in the manufacture of devotional wax candles by casting melted wax. If the candle body is formed in this way, it is desirable that the pin used for providing the centrally disposed hole through the candle body be somewhat larger than the wick to be inserted, for when the pressure used for compressing the wax particles is relieved and the pin about which the wax particles have been compacted is removed the hole which is left tends to become slightly smaller than the diameter of the pin. Because a candle body may be produced according to this invention using different types of mold and either with or without a wick that is caused to become embedded therein when the candle is formed, the term candle body as used herein and in the claims is intended to have a broad meaning as referring to any type of candle body, however produced, by compacting a friable mass of particles of wax or other waxy material and whether or not the candle body has a wick comprised therein.

In providing the wax in the form of a friable mass of wax particles it has been found that the atomization or spraying of melted wax into an atmosphere of air, as hereinabove described, possesses unique advantages as compared with other possible methods of reducing the wax to a finely divided flake, granular, or powdered condition. Air atomization of the melted wax not only is much more efiicient from the standpoint of convenience and economy, but also produces the wax so as to have optimum conditions as regards particle size and shape and the occlusion of intervening films of air between the particles whereby the particles may be successfully handled while they are being conveyed and charged into the pressure molding means. Moreover, the wax particles are produced in such form that during molding there is uniform expelling of excess air so as to result in the production of highly homogeneous candle bodies. It also has been pointed out above that by atomization into air moisture is eliminated and that this is highly advantageous in preventing occurrence of flaws in the formed candle bodies. From the point of view of economy, atomization into air is preferable, but substantially the same effect would be produced upon atomizing the melted wax into any other gaseous material.

While the production of the wax particles by atomization into air or other gaseous atmosphere has the special advantages hereinabove mentioned, certain features of this invention may be practiced using wax in the form of a friable mass of small particles that has been produced in other ways. For example, solid wax may be subjected to a grinding operation, but grinding is relatively diflicult to perform without resulting in agglomerated wax particles unless the wax is chilled so as to be Well below its melting point, and when chilling is resorted to there is likelihood of condensation occurring with resultant entrapment of moisture in the wax particles which are produced. It is also possible to produce wax in finely divided form by causing the wax to occur in the form of filaments or films which may, for example, be floated on water. However, even in such case ultimate grinding has to be resorted to. It is also possible to extrude wax through fine openings adjacent to which some comminuting device is operatively arranged, but any such operation is relatively expensive and likewise is difiicult to carry out without causing excessive premature agglomeration of the wax particles and in such a way as to have wax particles of that size and condition of aeration which make it possible to produce high-grade molded wax candles by pressure molding at atmospheric temperature.

In addition to a wax such as that known as white scale wax which is commonly used in the manufacture of devotional candles, any other wax or waxy material adapted for providing a candle may be employed, whether derived from animal, vegetable or mineral sources. For example, various types of parafin may be used or mixtures of paraffins. Stearic acid may also be employed in the manufacture of candles, either alone or in combination with parafiin or crude scale wax. Stcaric acid is frequently used in minor proportion for the purpose of improving the appearance of candles. In addition to the foregoing, there have been a number of proposals for formulating candle stock for the purpose of affording special properties as regards burning characteristics, color, odor, and so forth. Any waxy material adapted to be used in candles may be employed in the practice of this invention.

I claim:

1. A method of making a candle of waxy material which comprises introducing a friable mass of particles of said waxy material into a mold within which a wick is disposed so that said mass of particles surrounds said wick and compacting said mass of particles longitudinally relative to said wick within said mold to form a coherent candle body surrounding and adhering to said wick.

2. A method of making a candle of waxy material which comprises introducing a friable mass of particles of said waxy material into a mold within which a wick is disposed so that said mass of particles surrounds said wick, compacting said mass of particles longitudinally relative to said wick within said mold to form a coherent candle body surrounding and adhering to said wick, removing said candle body from said mold, suspending said candle body by said wick and while said candle body is so suspended applying a coating of waxy material thereto by dipping said candle body in a bath of melted waxy material, removing it from said bath with a retained coating of melted waxy material thereon and permitting said coating to harden by cooling.

3. A method of making a candle from a waxy material which comprises disposing a friable mass of particles of said material about a portion of a continuous length of wick, compacting said mass of particles longitudinally relative to said portion of said continuous length of wick to form a coherent candle body adherent to one part of said portion of said wick, leaving another part of said portion of said wick substantially free, and then severing said wick in said substantially free part in substantially spaced relation to said candle body.

4. A method of making a devotional candle from a Waxy material which comprises disposing a friable mass of particles of said material about a portion of a continuous length of wick, compacting said mass of particles longitudinally relative to said portion of said continuous length of wick while said wick is stationary to form a candle body adherent to part of said portion of said Wick leaving free wick extending from the top and bottom of the candle body, then advancing said candle body together with said continuous length of wick to a Wick base applying zone, applying a wick base to said free Wick extending from the bottom of said candle body in normally disposed relation therewith and substantially flush with the bottom of said candle body while said candle body and said wick are stationary, then further advancing said candle body and said wick substantially beyond said wick base applying zone and thereafter severing said free wick extending from the top of said candle body from said continuous length of wick at a point in adjacent spaced relation to the top of said candle body.

5. A method of making devotional candles from a waxy material which comprises molding a plurality of candle bodies at predetermined intervals of spacing along a continuous length of wick by successively compacting a friable mass of particles of said waxy material about said wick in a molding zone to form a candle body in adherent relation to said wick and advancing said candle body with said wick carried therewith from said molding zone to a holding zone, securing a wick base to said wick in normally disposed relation thereto and substantially flush with the bottom of the candle body while said candle body is in said holding zone and severing said wick on the opposite side of said base from the bottom of said candle in adjacent spaced relation thereto.

6. Apparatus for making Wax candles which comprises a mold for a candle body, means for holding a wick stationary within said mold and longitudinally centered with respect to said mold, means for introducing a friable mass of wax particles into said mold disposed about said wick and means for compacting the friable mass of wax particles Within said mold longitudinally with respect to said mold and with respect to said wick while said wick is stationary within said mold to form a candle body composed of at least partially coalesced wax particles disposed about said wick in bonded relation thereto.

7. Apparatus for making candles which comprises a mold for a candle body, means for holding a wick disposed within said mold, means for introducing a friable mass of wax particles into said mold disposed about said wick, and a piston slidable within said mold for compacting the friable mass of wax particles in said mold into the form of a candle body having said wick centrally disposed therein, said piston having an aperture therein through which said wick passes for permitting movement of said piston relative to said wick during compaction of said mass of wax particles in said mold.

8. Apparatus according to claim 7 which comprises mold end-closing means adapted to open and close the end of the mold opposite to said piston, said piston being slidable within said mold first to position for forming a candle body within said mold by compaction of said mass of wax particles within the mold when said endclosing means is in closed position and being slidable further in the same direction for ejecting the formed candle body from the mold when said end-closing means is in opened position, and wick supply means adapted to permit the ejection of said candle body from said mold while carrying therewith the wick embedded therein in unsevered relation to said wick supply means.

9. Apparatus for making wax candles which comprises a mold for a candle body, means for holding a wick within said mold, a piston slidable within said mold between retracted and advanced positions, said piston having an aperture therein though which said wick passes 'and being movable relative to said wick in the direction of the disposition of said wick, means for introducing into said mold a friable mass of wax particles disposed about said wick when said piston is in retracted position, said piston being adapted to coact with said mold for compacting said wax particles therein about said wick when said piston is moved from said retracted position to said advanced position, means for effecting reciprocatory movement of said piston between said retracted and said advanced positions, and vent means for venting wax particles and air from said mold during travel of said piston from said retracted position to said advanced position.

10. Apparatus for making wax candles which comprises pressure molding means adapted to compact a friable mass of wax particles into the form of a candle body about a centrally disposed wick, feed means adapted to feed a friable mass of Wax particles to said pressure molding means, means for feeding a continuous strand of wick to said pressure molding means, holding means adapted to hold a candle body formed by said pressure molding means, means for moving a candle body and wick embedded therein from said pressure molding means to said holding means, means for attaching a wick base to wick protruding from the bottom of said candle body while said candle body is held by said holding means and means for severing the wick in adjacent spaced relation to said base while said candle body is held by said holding means.

11. A method of making a candle of Waxy material which comprises the steps of disposing a Wick substantially at the axis of a tubular candle mold with a continuous extension from one end thereof, filling the mold with a friable mass of particles of said waxy material disposed substantially uniformly about said wick, compacting said particles longitudinally relative to said Wick to form a coherent candle body surrounding and adherent to said wick, and then moving the molded candle body out of the other end of the mold With simultaneous movement of a succeeding portion of said wick into said mold.

12. A method of making a candle of waxy material which comprises the steps of successively forming candle bodies on a continuous wick in spaced apart relation, applying a wick base to the wick substantially at the bottom of each candle body, and after said base has been attached severing the wick adjacent said base and between said base and the top of next adjacent candle body.

13. Apparatus for making candles which comprises a mold for a candle body, removable closure means for one end of said mold, a piston mounted for being inserted into the other end of said mold to compact wax particles therein and to be retracted from said end of said mold, said piston having an aperture therein for passage of a wick therethro-ugh into said mold and for permitting relative movement of said piston and said wick, wick supply means for supplying wick through said aperture into said mold, wick-holding means carried by said removable closure means adapted to hold a wick therein in position substantially centrally of said mold when said closure is in position to close said mold and to be separated from said wick when said wick is in said position, means for charging a friable mass of wax particles into said mold when said piston is retracted from said mold and while said wick is supported substantially centrally of said mold by said holding means and said aperture in said piston and candle-holding means in substantial axial alignment with said mold in adjacent relation to said closure means, said piston being mounted for movement so as to propel a candle body formed in said mold from said mold when said closure is open to said holding means to be held thereby.

14. Apparatus for making candles which comprises means for supplying a continuous Wick, means for distributing wax particles in friable form about said wick, and means for compacting said particles longitudinally 18 with respect to said wick into a succession of spacedapart candle bodies connected by said wick and adherent thereto.

15. A method of making a candle of waxy material which comprises compacting a friable mass of particles of waxy material which has a melting point between about F. and about F. and which is at a temperature at least about 30 F. below its melting point, said mass of particles being disposed about a centrally disposed wick, by a compacting pressure of from about 40 to about 100 pounds per square inch applied for compaction of the mass of particles longitudinally of the wick to form a candle body wherein the wax particles are partially coalesced, venting gaseous material from the mass of particles substantially throughout said compaction, and after formation of the candle body eifecting substantial additional coalescence of said particles by tempering the candle body at a temperature substantially below the melting point of the waxy material.

References Sited in the file of this patent UNITED STATES PATENTS 29,506 Meyrose Aug. 7, 1860 873,073 Nordfors Dec. 10, 1907 1,571,589 Kerr Feb. 2, 1926 1,588,992 Ragioneri et a1. June 15, 1926 1,622,347 Rhoads Mar. 29, 1927 1,773,257 Buse Aug. 19, 1930 2,287,029 Dowdell June 23, 1942 2,298,913 Arden Oct. 13, 1942 2,324,723 Powers July 20, 1943 2,360,275 Race Oct. 10, 1944 2,481,019 Joyce Sept. 6, 1949 2,635,294 Rolaston Apr. 21, 1953 2,679,069 Keogh May 25, 1954 2,697,247 Bettes Dec. 21 1954 2,697,249 Bettes et a1 Dec. 21, 1954 FOREIGN PATENTS 684,942 Great Britain Dec. 24, 1952 

